Evacuated sensor device for detecting microorganisms in blood samples, and method thereof

ABSTRACT

A device and method allow for collection of a blood specimen and for detecting the presence of microorganisms in the blood specimen. The device, a sensor plate under vacuum, provides an environment to culture microbial organism colonies from a blood sample, and a means to facilitate microbial detection and quantification, either manually or with an instrument. The vacuum sensor plate has a microorganism immobilization matrix layer and a sensor layer. Detected microbial colonies are immediately available for further testing. A kit is provided having a needle assembly for direct draw of blood from a patient onto the immobilization layer within the vacuum sensor plate. The sensor plate provides an area for accepting a blood sample, a mechanism to immobilize the blood sample on an interior surface of the plate, nutrients to facilitate growth of microorganisms in the sample, and a sensor layer for allowing the detection and/or enumeration of microorganism colonies within the blood sample.

This application is a continuation-in-part of U.S. patent application Ser. No. 08/989,560 filed Dec. 12, 1997, to Jeffrey et al., the subject matter of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The presence of microbial contamination in clinical specimens is conventionally determined by culturing the specimens in the presence of nutrients and detecting microbial activity through changes in the specimen or in the atmosphere over the specimen after a period of time. For example, in U.S. Pat. No. 4,182,656 to Ahnell et al., the sample is placed in a container with a culture medium comprising a carbon 13 labeled fermentable substrate. After sealing the container and subjecting the specimen to conditions conducive to biological activity, the ratio of carbon 13 to carbon 12 in the gaseous atmosphere over the specimen is determined and compared with the initial ratio. In U.S. Pat. No. 4,152,213, a method is claimed by which the presence of oxygen consuming bacteria in a specimen is determined in a sealed container by detecting a reduction in the amount of oxygen in the atmosphere over the specimen through monitoring the pressure of gas in the container. U.S. Pat. No. 4,073,691 provides a method for determining the presence of biologically active agents, including bacteria, in a sealed container containing a culture medium by measuring changes in the character if the gaseous atmosphere over the specimen after a period of time.

A method for non-invasive detection is taught by Calandra et al., U.S. Pat. No. 5,094,955, where a device is disclosed for detecting the presence of microorganisms in clinical specimens, such as blood or other body fluids, and in non-clinical specimens, by culturing the specimens with a sterile liquid growth medium in a transparent sealed container. The presence of microorganisms is determined by detecting or measuring changes in the pH of the specimen or the production of carbon dioxide within the specimen using a sensor affixed to the interior surface of the container or to the sealing means used to seal the container. In Calandra et al., microorganisms can be detected in the presence of interfering material, such as large concentrations of red blood cells, through non-radiometric and non-invasive means.

With the detection system of Calandra et al. and others like it, the time required for detecting the presence of microorganisms is related to the number or type of microorganisms within the sample. Also, such a system allows for the determination of the presence of microorganisms, but does not allow for enumeration. Furthermore, it is often the case that after detection of microorganisms, it is desired to identify the microorganisms and/or determine their susceptibility to various antibiotics. In a Calandra-type system, plating-out the microorganisms from the liquid culture medium before performing susceptibility or identification tests, involves additional time--time that is not always available if the patient is very ill.

SUMMARY OF THE INVENTION

The present invention relates to a device and method for detecting the presence of microorganisms in blood specimens. The device, hereinafter referred to as the "sensor plate", provides an environment to culture microbial organism colonies from a liquid blood sample, and a means to facilitate microbial detection and quantification, either manually or with an instrument. The sensor plate is under vacuum and comprises a solid, semi-solid or powdered gel immobilization matrix layer and a sensor layer. Detected microbial colonies are isolated and immediately available for further testing.

More particularly, the sensor plate can provide an area for accepting an unknown blood sample (unknown whether microorganisms are present or not), a mechanism to immobilize the blood sample on an interior surface of the plate, components (e.g. nutrients) to facilitate growth of microorganisms in the sample, and a sensor for allowing the detection and enumeration of microorganism colonies within the sample. The sensor plate can be comprised of an immobilization layer (e.g. a gel layer) and a sensor layer, with a sample being absorbed into, or forming a gel with, the immobilization matrix layer. A sensor layer can be located on at least one surface of the sensor plate to indicate the presence of microorganisms. Small areas or zones of color changes occur in the sensor layer which indicate actual microorganism colony growth in the immobilization layer. The sensor plate is inspected manually or automatically with an instrument to determine the presence, location and/or number of microorganism colonies.

In a preferred embodiment of the invention, the sensor plate is constructed so as to allow direct draw of blood from a patient onto the plate. The plate can be equipped with a pierceable member, which when pierced by a first end of a needle assembly (having a second end inserted into a vein of a patient), will result in blood flow into the evacuated sensor plate device. The plate can also be provided with a cylindrical elongated member extending from the sensor plate device, which elongated member is of the same size as a standard evacuated blood collection tube. This embodiment allows for blood collection using a standard hospital adapter.

Various other features and advantages of the invention will become apparent from the detailed description below taken in conjunction with the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of the sensor plate device;

FIG. 2 is a cross section of the sensor plate device;

FIG. 3 is a cross section of an alternative embodiment of the sensor plate device;

FIG. 4 is a cross section of a further alternative embodiment of the sensor plate device;

FIG. 5 is an illustration of kit having a needle assembly for venipuncture and a vacuum sensor plate;

FIG. 6 is an illustration of a "roller bottle"2-type sensor plate;

FIG. 7 is a cross sectional view of the embodiment of FIG. 6;

FIG. 8 is an illustration of the sensor plate that can be opened by means of clamps; and

FIG. 9 is an exploded view of the sensor plate of FIG. 8.

FIG. 10 shows the bottom of three sensor plates positive for E. coli;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is an illustration of sensor plate 1 which can be in the form of a flat, shallow container with at least one side (e.g. the bottom side) being transparent or translucent. The container is preferably a sealed evacuated container, and preferably with a volume of headspace above the sensor plate layers. The container can be provided with a port 2, which may be sealed with a stopper 3, screw-cap, septum, or any combination thereof (or any other sealing device). Once a blood sample is collected into the container, the sensor plate can be configured as either a gas-permeable or a gas-impermeable container, depending on the growth requirements of the microorganism. This configuration is accomplished by using different plate composition materials, laminates (gas impermeable and/or hydrophobic gas-permeable membranes), and/or configurable vents (e.g. a gas permeable membrane in an opening of the container wall).

Within the container of the sensor plate device, are one or more layers which help to immobilize/absorb the sample so that colonies of microorganisms can grow localized, which increases the ability to detect the colonies of microorganisms. When it is stated that this layer is for immobilizing a sample, this means that at least part of the sample is immobilized (there could be excess sample remaining on top). In one embodiment, at least one layer in the device has matrixes which adversely affect visualization of microorganisms. As can be seen in FIG. 2, provided are an immobilizing layer (matrix layer) 10 and a sensor layer 12. These two layers, which will be described more fully hereinafter, can also be combined together into a single layer, although it is preferred that the two layers be provided separately. As also shown in FIG. 2, is the plate bottom 14, which is preferably transparent for viewing/imaging changes in the sensor layer due to microorganism growth.

The sensor layer 12 is provided for the purpose of indicating the location of microbial growth by providing a tightly localized dramatic change in the ultraviolet, visible, and/or infrared spectrum. This localized change is detectable on the surface of the plate, opposite the sensor surface near the microbial growth. The sensor layer comprises a material that undergoes a change in a detectable property (e.g. an indicator) which is embedded on and/or in a matrix (support material) which is preferably opaque. By "opaque", it is meant that the sensor layer sufficiently blocks the viewing or detecting (in any relevant electromagnetic region) of the test sample and/or actual microorganism colonies immobilized in the immobilizing layer from the opposite side of the sensor layer (e.g. semi-opaque, substantially opaque, or fully opaque). Although it is possible to have a transparent or relatively transparent sensor layer if the test sample is also substantially transparent (in which case the sensor layer undergoes localized changes from transparent to opaque in the presence of microorganism colonies), it is preferred that the sensor layer not be transparent. Improved results are obtained in detecting microorganisms in test samples that could interfere with detection if the sensor layer is opaque. If the test sample itself interferes with visualizing/detecting (e.g. with the eye or with an instrument) the presence or growth of microorganisms directly in the immobilization layer, then it is preferable that at least one of the immobilization layer or the sensor layer (preferably the sensor layer) is capable of blocking detection/visualization of the actual test sample and/or actual microorganisms, and instead a user detects changes in the sensor layer which correspond to presence/growth of microorganisms in the immobilization layer. The immobilization layer can also be opaque, and in one embodiment of carrying out the invention, the sensor layer, the immobilization layer, and the sample are all opaque.

The sensor comprises a solid composition or membrane, with an indicator medium immobilized on or within it. The sensor layer is preferably located flush against the inside surface of the container, or in the sealing means used to seal the container or attached to the sealing means, such that the sensor layer is visible from outside. It is preferably affixed to the container to prevent cells, proteins, other solids or other opaque or colored components from getting between it and the container surface. In certain embodiments the sensor layer is separated from the specimen and its growth medium by a membrane or other solid layer.

One embodiment of this invention comprises a sealing means, such as a lid or cap, which may be transparent or which may have a transparent section. The sensor can be placed in proximity to the transparent lid or section of lid or is made part of the lid. When the lid is used to seal the container, the changes in indicator are read through the transparent sealing means. The sealing means may also be made of a material, such as a polymer, which contains encapsulated indicator micelles. A transparent section in either the container or the sealing means is not needed, as long as the material is permeable to the changes caused by metabolism of the microorganisms, and the changes in the indicator are visible on the surface of the sealing means.

Microorganisms in specimens of body fluids, such as blood, containing as few as one organism per total sample volume, can be detected using this invention. Such specimens may require a number of days of incubation before the population of organisms reaches a critical level and where a change in a parameter involved in microorganism metabolism can be measured.

The sensor is useful in that: 1) changes in the sensor layer due to microbial metabolism (e.g., increases or decreases in a component due to metabolism) are detected from the immobilizing layer rather than in the atmosphere over the specimen, 2) because the sensor is affixed to the interior surface of the plate or the closure or sealing means or attached through the outside of the closure or sealing means, measurements can be made from outside the transparent wall of the plate or the sealing means without having to violate the integrity of the plate, 3) the external measurements can be made by visual inspection or with an instrument that measures by reflectance, fluorescence, and etc., or by image capture, 4) opaque/colored or fluorescent components in the specimen do not interfere with the ability to detect changes or the measurement of those changes, and 5) a high concentration of indicator molecules can be maintained within a small volume in the sensor (e.g., within the polymer emulsion or on the membrane), such that a change can be easily observed or detected.

The nutritional components that make up a complex microbial medium influence the metabolic pathways used by microorganisms. Organic acids, bases and various gases can be produced by microorganisms in proportions dependent on the nutrients available. These products also vary from species to species of microorganism. The presence of these products in the immobilizing layer can change its pH. The sensor layer used in the invention could contain pH sensitive indicators that give a measurable change in response to a pH change. Or, the consumption or production of metabolites that affect the pH of the indicator, such as CO₂ or NH₂, could be measured. Microbial growth can also be detected by measurement of changes in other metabolites such as O₂. These changes can be detected by measuring, for example, fluorescence. The sensor layer can be designed to respond to decreases in O₂ concentration due to metabolism of microorganisms. And an indicator could be selected that undergoes a change in fluorescence rather than a change in color or other parameter. Carbon dioxide is a commonly produced by most organisms and, therefore, is preferred for detection of microbial growth. Whatever mechanism is utilized, in a preferred embodiment, the sensor layer will undergo a detectable change in response to the presence and/or growth of most microorganisms.

The indicator can be attached either covalently or non-covalently to a support medium. Alternately, the indicator can be encapsulated within a polymer matrix such as being emulsified within a polymer matrix prior to curing.

The sensor layer is preferably affixed inside a suitable transparent vessel or a transparent sealing means, with an appropriate adhesive, if necessary. They may also comprise an integral part of the sealing means or be affixed to the sealing means or within the vessel as an indicator emulsified within a polymer matrix cured in situ. They can also be placed outside the container, as long as a method is provided that allows the metabolic changes due to the microorganisms, to affect the sensor.

A variety of different fluorescent and visible pH indicators can be used as the active molecular species in pH, H₂, H₂ S, NH₃, O₂ or CO₂ sensors. Generally, the only limitations on the selection of indicators are the requirements that they have acceptable dynamic ranges and wavelength changes that are detectable by infrared, fluorescence, reflectance, transmittance and/or imaging technologies.

Sensors for detecting pH changes in the culture medium according to the invention preferably exhibit a change in fluorescence intensity or visible color over a pH range of about 5.0 to about 8.0.

Indicators for a CO₂ sensor should exhibit a change in infrared intensity, fluorescence intensity or visible color preferably between about pH 13 and about 5, and most preferably between about pH 13 to about 9, in order to detect changes in CO₂ concentration.

pH indicator molecules bound covalently or non-covalently to a support medium that retain their pH indicating properties are preferred. Indicators belonging to the xanthene, phenolphthalein and phenolsulfonphthalein groups are useful. Examples of these include fluorescein, coumarin, phenolphthalein, thymolphthalein, bromothymol blue, thymol blue, xylenol blue, ortho cresolphthalein and α-naphthol benzein.

The support medium can be a substance such as cellulose or certain silicones, to which a pH indicator can be covalently attached using organic reactions. Non-covalent attachment of pH indicators can be achieved using ionic support materials, such as nylon membranes that have a positive or negative zeta potential. Other ionic support materials that can be used are positive or negatively charged ionic resins, such as diethylamino ethyl (DEAE) resin or DEAE cellulose. Pretreatment of the support material with a protein may be required if the indicator membrane is to be in direct contact with microbial growth medium. Non-covalent attachment of pH indicators can also be achieved using lypophilic support materials, such as polystyrene or hydrophobically modified polymers. The pH indicators may contain long chain aliphatic groups which may bind support material through hydrophobic interactions.

The pH indicator sensors directly detect pH changes due to the pH environment of the microbial growth medium. However, these sensors can be made to selectively react to gases (e.g., carbon dioxide, ammonia, hydrogen, hydrogen sulfide, or oxygen) due to microorganism metabolism. A selectively semi-permeable composition or membrane could be provided on the sensor layer, such as silicone, latex, teflon, or various plastics characterized by the capacity to selectively permit the diffusion of a gas while preventing the passage of ions. For sensors comprising indicator encapsulated within a polymer matrix, the polymer forming the matrix can act as the semi-permeable barrier that permits the passage of gases but not ions.

In one embodiment, the CO₂ sensor is comprised of a plurality of components. The first component is a visual or fluorescent pH indicator, which is reactive at the pH range between 6 and 10. Examples of indicators meeting these criteria are bromothymol blue, thymol blue, xylenol blue, phenolphthalein, ortho cresolphthalein, coumarin, and fluorescein. A second component, if necessary, is an acid, base or buffer, which maintains an optimal pH environment for detection of CO₂ by the selected pH indicator. A third component can be glycerol or an equivalent emulsifier, which can produce droplets of indicator solution emulsified within the uncured polymer. A fourth component can be a pigment, such as titanium oxide, zinc oxide, magnesium oxide, ferrous oxide, etc. A fifth component can be an uncured polymer such as silicone, which maintains a proper environment for the indicator. Any polymer can be used that does not affect too greatly the chemical activity of the indicator, either from its own chemical or physical properties or its requirements for curing, as long as it is permeable to gases but not ions, and does not have these properties altered when subjected to sterilization. Other silicone polymers that are also satisfactory are those that are cured by high temperature, by catalytic activity, or by ultraviolet vulcanization. An emulsion is prepared from the various components and the polymer is cured to form a semipermeable matrix around the droplets of pH indicator, which permits selective diffusion of CO₂ and other gases from the immobilization layer, resulting in localized measurable changes in the sensor layer . The sensor layer can be prepared separately, such as in a mold, cured, and then attached to the plate with an appropriate adhesive, such as a silicone adhesive. Alternatively, and preferably, the sensor is formed on the bottom of the container and cured in situ. After curing, the container with the sensor can be sterilized, such as by autoclaving or gamma radiation. Conveniently, the immobilizing and additional optional layers can be introduced into the sensor plate device before sterilization and thus also be sterilized by that process.

In a further example, the sensor layer comprises an indicator solution emulsified in a pigmented silicone matrix. The indicator solution is comprised of thymol blue indicator (e.g. 0.33 g or 0.65 g) dissolved into a solution of 0.8M (or 1.0M) potassium hydroxide (10.0 ml) and, optionally, isopropyl alcohol (10.0 ml). The indicator solution (5.0 g) is then mixed with the pigmented silicone components. The pigmented silicone matrix is comprised of Sylgard 184™ silicone (components A (50.0 g) and B (5.0 g)) and white pigment (part #61-18000, Ferro Corp., N.J.) (1.0 g). The sensor material is then poured and spread onto a plate in a thin layer (approximately 0.2 to 0.5 mm).

In another example, the sensor layer comprises an indicator solution mixed with a pigmented silicone matrix. The indicator solution is comprised of ortho-cresolphthalein indicator (2.0 g) dissolved into a solution of isopropyl alcohol (5.0 ml) and 0.9M potassium hydroxide (5.0 ml). The indicator solution (2.5 g) is then mixed with the pigmented silicone components. The pigmented silicone matrix is comprised of Sylgard 184™ silicone (components A (25.0 g) and B (2.5 g)) and white pigment (part #61-18000, Ferro Corp., N.J.) (0.5 g). The sensor material is then poured and spread onto a plate in a thin layer (approximately 0.2 to 0.5 mm). In a variation of this example, the above ortho-cresolphthalein sensor layer is covered with an overcoat layer comprising the pigmented silicone matrix.

In still another example, the sensor layer is composed of an indicator solution mixed with a pigment solution and a silicone matrix. The indicator solution is comprised of ortho-cresolphthalein indicator (2.0 g) dissolved into a solution of isopropyl alcohol (10.0 ml), and 0.8M potassium hydroxide (10.0 ml). The pigment solution is comprised of silicone oil (40.0 g), white pigment (part #61-18000, Ferro Corp., N.J.) (4.0 g). The silicone matrix is comprised of Wacker Elastosil RT 601™ silicone (components A (200.0 g) and B (20.0 g)) and toluene (40.0 g). The indicator solution (20.0 g) is then mixed with the pigment solution (40.0 g) and silicone components. The sensor material is then sprayed onto a plate in a thin layer (approximately 0.1 to 0.3 mm thick).

In addition to indicators responsive to changes in oxygen, carbon dioxide and pH, as mentioned above, indicators could also be utilized that detect changes in ammonia, oxidation-reduction potential, hydrogen, hydrogen-sulfide, or any other substance that undergoes a change due to the presence or growth of microorganisms. Also, a plurality of different indicators could be used in the sensor layer (or in a plurality of sensor layers).

The sensor layer is preferably opaque so as to prevent properties of the sample (e.g. natural fluorescence, opacity, etc.) from affecting or masking the response of the sensor. The sensor layer preferably changes from one opaque state to another opaque state in the presence of microorganisms, with the change being a detectable change by image capture and processing. As one example, the sensor layer could be an emulsified mixture of ortho cresolphthalein indicator in a white pigmented silicone matrix, with an overlay of white pigmented silicone. Or, the sensor layer could be a pigmented silicone matrix emulsified with one or more indicators such as thymol blue indicator, a xylenol blue indicator, or a "universal" indicator. The matrix in the sensor layer could be a suitable latex, polyurethane, nylon membrane (e.g. charged nylon membrane) or cellulose powder. The sensor layer matrix could also be a silicone matrix, such as Sylgard 184™, Wacker 601™, or Wacker 934™. Or, the sensor layer could be made up of two layers, such as an indicator layer and an opaque layer.

The other main layer in the sensor plate device is the immobilizing layer 10. The purpose of the immobilizing layer is to immobilize organisms in the sample either within a matrix or on the surface of a matrix. The blood sample drawn from a patient is a liquid. Such a liquid sample can be mixed with a dry powdered gelling agent to form an organism-immobilizing gel matrix when mixed. The blood sample is preferably added to a dry powdered gelling agent already provided as a layer in the sensor plate device. However, a blood sample could also be mixed with a dry powdered gelling agent, and then both immediately added to the sensor plate device before gelling has occurred. Also, a blood sample could be applied onto an already gelled matrix, or onto a dehydrated or partially dehydrated gel matrix so as to immobilize the microorganisms on the surface of the gel. A gelling agent could also be imbedded in a support matrix to add physical support. Examples include glass or cellulose synthetic polymer fibers either mixed throughout or in the form of woven or non-woven fabrics. Also, in order to immobilize a sample, the immobilization layer need not be a gelling agent, but rather could comprise a non-gel absorbent material, such as sponge materials, celluloses, glass fibers, filter paper, etc.

More than one gelling agent could be utilized in the sensor plate device, either mixed together or as separate layers. For example, a mixture of guar gum and xanthan gum, combined by weight at an approximate ratio of 2:1, could be used. Other gelling agents could be used singly or in combination, including natural and synthetic hydrogel powders. One or more gelling agents could be combined together selected from gums, agars, agaroses, carageenans, bentonite, alginates, collagens, gelatins, fused silicates, water soluble starches, polyacrylates, celluloses, cellulose derivatives, polyethylene glycols, polyethylene oxides, polyvinyl alcohols, dextrans, polyacrylamides, polysaccharides (synthetic or natural) or any other gelling or viscosity enhancing agents.

Dehydrated and/or partially dehydrated gel matrices for surface colony isolation/immobilization could be used, including one or more synthetic or natural hydrophilic polymers. If more than one gelling agent is used, such could be mixed together or provided in a plurality of layers. In one example, an upper layer could be provided to trap microorganisms on the surface, and a lower layer could be provided as a wicking agent to draw the liquid sample through the upper layer (e.g. a thin agar layer over a modified cellulose absorbent, or a porous hydrophilic membrane over an absorbent pad, polymer or hydrogel).

The immobilization layer must not adversely affect the sensor layer. If the sensor layer undergoes a detectable change due to a pH change, then a very acidic gel layer could adversely affect the sensor layer (also some manufacturing processes are acidic and could leave an acid residue that could adversely affect the sensor layer). Furthermore, if the immobilization layer is a powdered gel layer, it should be certain that this layer does not turn acidic when mixed with a blood sample, as this could also cause the sensor layer to change even in the absence of microorganisms.

As can further be seen in FIG. 2, an optional conditioning layer 16 can be provided on (or within or below) the immobilizing layer. Though illustrated separate from the immobilization layer in FIG. 2, the conditioning materials from the conditioning layer are preferably incorporated into the immobilization layer itself. Conditioning components, whether provided within the immobilization layer or in a separate layer, can include one or more of media for microorganism growth, lytic agents, lytic enzymes, antibiotic neutralizers, surfactants or other materials helpful for improving microorganism detection capabilities. Conditioning components can also be provided both within the immobilization layer and in a separate layer in the same sensor plate device.

Lytic agents for conditioning can be added for lysing blood cells in the test sample, for allowing for a smoother gel, and/or for better rehydration of the gel. Examples of possible lytic agents include saponin, digitonin, Tweens™, polysorbitan monolaurate, and other surfactants. Lytic enzymes, typically (though not necessarily) proteolytic enzymes, may be added for digesting cellular material in a blood sample, for making a smoother gel, and/or for better rehydration of the gel. The lytic enzymes for conditioning can include one or more proteases, for example an enzyme mixture derived from Aspergillus oryzae, or the like.

Toxin neutralizers may be added for conditioning, in particular for faster and/or better recovery of microorganisms in the test sample. One or more of such neutralizers could be selected from resins, gums, and carbon-based materials (e.g. activated charcoal or Ecosorb®), or one of a variety of enzymes to specifically degrade various antibiotics (e.g. beta lactamase).

Media can also be added for conditioning (whether directly to the immobilization layer or separately). Media is added to provide nutrients for the growth of microorganisms. Though many types of media for different types of microorganisms could be used, if the microorganism is an aerobic organism, the media could include, as one example (an exemplary amount of each being listed in parentheses in g/l): tryptone (17), soytone (3), proteose peptone (5), malt extract (2.5), dextrose (2.5) and MOPS (23). If the microorganism is an anaerobic organism, the media could further include the media listed above for aerobic organisms, as well as Hemin (0.005), L-cystine (0.2), Na-m-bisulfide (0.2) and Menadione (0.0005).

For Coliforms, the media could include, as an example, Lactose (5), bile salts #3 (0.8), K₂ HPO₄ (7), KH₂ PO₄ (3), (NH₄)₂ SO₄ (0.5), MgSO₄ (0.1), Na-m-bisulfide (0.4) and SDS (0.1). For yeast, mold and other acid tolerant microorganisms, the media could include, as one example, dextrose (10), yeast extract (10), (NH₄) citrate (2) and tartaric acid to a pH of 5.5.

As can be further seen in FIG. 2, a wall of the container can be provided with apertures 20, below which is a hydrophobic gas-permeable film 22, and above which is a gas-impermeable (removable) film 24. Or, the container could be provided with an opening in a wall thereof with the gas-impermeable film and the hydrophobic gas-permeable film adhered together covering the opening. If the organism is anaerobic, the gas-impermeable film would be left in place. However, if the organism is aerobic, the gas-impermeable film would be removed at the time of the addition of a test sample to the sensor plate device. Of course, the hydrophobic gas-permeable film need not be provided at all, though it is beneficial for preventing contaminants from entering the container, and for preventing potentially infectious test material from leaking out of the device.

Area A in FIG. 2 is illustrated in further detail in FIGS. 3 and 4. As can be seen in FIG. 3, in a further embodiment of the sensor plate device, in place of a single immobilization matrix layer, there can be provided one or more of: an isolation gel layer 30 for a semi-rigid surface to allow surface capture and recovery after growth, an adhesive layer 31, an absorptive gel layer 32 and an additional adhesive layer 33. The absorptive gel layer 32 can include one or more of conditioning components (in gels), media for microorganism growth, lytic enzymes, and antibiotic neutralizers. As can be further seen in FIG. 3, in place of a single sensor layer, there can be provided one or more of: an overcoat layer 34, an adhesive layer 35, an indicator layer 36, and an additional adhesive layer 37 in contact with plate bottom 38.

In an additional embodiment of the invention as illustrated in FIG. 4, provided is a matrix layer 40 which comprises: a gelling powder, and dry conditioning components such as media, lytic enzymes and antibiotic neutralizers. As in FIG. 3, in place of a single sensor layer, there can be provided one or more of: an adhesive layer 41, an overcoat layer 42, an adhesive layer 43, an indicator layer 44, and an adhesive layer 45 in contact with plate bottom 46.

The size of the sensor plate device can be varied depending upon the desired sample size. In one example, a sensor plate device has an immobilization layer of the dimensions of 74 mm×117 mm. If the immobilization layer comprises a wet-type gel, then the sample size could be made very small (e.g. 1 ml or less), or, such as with a blood sample, the sample size could be up to 15 ml. On the other hand, if the immobilization layer comprises a dry powdered gel, then the sample size could be even greater, depending upon the amount of the powdered gel (e.g. the sample could be 30 ml or more).

Because the invention works particularly well with opaque samples, the sensor plate can be used with blood samples, and can be adapted for direct draw (venipuncture) from a patient. As can be seen in FIG. 5, a needle 50 is provided for insertion into a patient. A direct draw line 52 is in communication with the needle 50 and a piercing means 53. The piercing means 53 pierces a septum 54 in neck 56 of the sensor plate. Sensor plate 1 in FIG. 5 is a vacuum sensor plate, such that being under vacuum, when piercing means 53 pierces septum 54, blood is drawn into the sensor plate for culturing/microorganism detection. The sensor plate under vacuum need not have neck portion 56, however, if neck portion 56 is provided with the same dimensions as a standard Vacutainer™ tube, then the vacuum sensor plate can easily be used with standard hospital adapters for direct draw of patients' blood. The various layers within the sensor plate illustrated in FIG. 5 would be the same as previously described herein in detail in relation to FIG. 1.

A variation of the invention illustrated in FIG. 5, is illustrated in FIG. 6. As can be seen in this figure, a needle 50, direct draw line 52 and piercing means 53 are provided as in FIG. 5. A stopper/septum 64 is provided at one end of roller bottle 60. The stopper/septum 64 could also be provided in a neck extending from the roller bottle 60, such as illustrated in FIG. 5. The roller bottle 60 is essentially a sensor plate as illustrated in FIGS. 1 or 5, except that it is in a cylindrical or substantially cylindrical shape. Growth of microorganisms are detected by moving a camera etc. around the roller bottle, or, more easily, rolling the bottle past a line-scan camera or other detection assembly.

As can be further seen in FIG. 7, a cross sectional view of the roller bottle of FIG. 6, outermost layer 71 is the cross section of the bottle (glass, plastic, etc.), whereas adjacent layer 73 is the sensor layer. Layer 75 is a matrix layer, and innermost layer 77 is a conditioning layer. The actual layers provided in the roller bottle, and the makeup of the various layers, can be the same as that described hereinabove in relation to the flat sensor plate.

If a gas permeable membrane is provided for aerobic culturing of microorganisms within the roller bottle illustrated in FIG. 6, then the end of the cylindrical roller bottle (not shown) opposite from the septum end of the roller bottle, would be provided with a gas permeable film and a removable gas impermeable film to be removed after the direct draw of blood into the bottle. Obviously, removal of the gas impermeable film to expose the gas permeable film prior to the drawing of blood, will result in loss of vacuum within the bottle.

FIG. 8 and exploded view FIG. 9 illustrate additional details of the invention, such as clamps 81a-d, for holding top portion 83 of the sensor plate tightly on bottom portion 84. Other means for keeping the top and bottom portions held together are also envisioned (removable seal, screw mechanism, etc.). The fact that the plate is under vacuum also helps to keep the top and bottom portions together. An O-ring 90 also helps to maintain a seal between the top and bottom plates. Also illustrated are removable gas impermeable film 85 covering a gas permeable film 86. The gas permeable and impermeable films can be provided immediately adjacent each other, as illustrated in FIG. 9, or preferably with a rigid support on one or both sides of the gas permeable film. The support could be in the form of a mesh screen or the like, or simply be in the form of perforations in the wall of the sensor plate (see, e.g. layers 20-24 in FIG. 2). The gas permeable and impermeable films could cover an entire wall of the sensor plate. Also illustrated are neck 56 with septum, and septum 91 which forms a substantially flat surface with a wall of the sensor plate device. Either or both of these means can be provided for allowing the passage of a blood sample into the vacuum sensor plate.

The sensor plate being under vacuum can be an evacuated or partially evacuated container. The pressure should be less than atmospheric or ambient pressure, preferably from 0 to 12 psi, and more preferably between 1 and 11 psi. Though the pressure can be kept at 6 psi or less, it is important that the pressure be sufficient to draw a desired sample volume into the vacuum sensor plate. This is more important than the actual pressure needed, which varies depending upon the volume of headspace.

Because the sensor device is under vacuum, it is desirable to ensure that the material from which the container is made is sufficiently gas impermeable to hold the vacuum, and is sufficiently transparent (at least at the surface adjacent the sensor layer) to read the localized changes in the sensor layer. The container could be made of glass, though preferably a plastic material would be used. Some of the possible plastic materials included BAREX 210™ (BP Chemicals), BAREX 218™ (BP Chemicals), polyethylene terephthalate (PET: e.g. from Eastman Chemical Co.), polyethylene terephthalate with glycol termination (PETG: e.g. from Eastman Chemical Co.), or polyethylene naphthalate (PEN: e.g. from Eastman Chemical Co.). Other possibilities include polyvinyl chlorides (PVC), polystyrenes (PS), polycarbonates, polypropylenes, or any mixtures or combined layers of the above examples. Also possible are gas permeable plastics with gas impermeable laminates (e.g. Daran/Saran™ (Dow Chemical). Almost any plastic can be used that is non-toxic to microorganisms, sufficiently transparent (to view/read the sensor layer), sufficiently gas impermeable (sufficient to maintain an evacuated or partially evacuated container interior for the desired shelf-life), sufficiently easy to mold into the desired shape, and sufficiently rigid to resist deflection when evacuated. Though rigidity of the plastic is important, the strength of the plastic can be supported by pegs, ribs, or the like which extend between the top and bottom surfaces of the vacuum container so as to prevent flexing of the container walls when evacuated.

In use, a blood sample is taken from a patient and introduced into the vacuum sensor plate device. The sample is "conditioned" (if desired) as it spreads across the bottom surface of the sensor plate. The sample is absorbed into, or forms a gel with, an immobilization matrix layer. The sensor plate is then incubated, promoting the growth of microorganism colonies. A sensor layer located toward a bottom surface of the sensor plate device, undergoes a detectable change so as to indicate the presence of microorganism colonies. Finally, the sensor plate device is inspected manually or automatically to determine the presence and location of microorganism colonies.

If the sensor plate device is inspected automatically, an instrument is provided which performs three main functions: plate incubation, image acquisition/capture, and image processing. The instrument provides a controlled environment for incubating plates, which can include a heater if incubation is to take place at an elevated temperature from ambient (though an elevated temperature is not necessary in all situations). A blood sample is taken from a patient by direct draw into the sensor plate device, after which the sensor plate is placed in the instrument where it is subsequently sensed/observed by an image acquisition/capture device (e.g. a camera or scanner) during the incubation period. Images of the bottom of the sensor plate device can be captured at regular predetermined intervals and subsequently analyzed using one or more image processing techniques and algorithms to determine whether a microorganism colony is present on the sensor plate.

Feasibility studies of a number of different types of sensor plate devices have shown good detection results: E. coli detected in approximately 9 hours, E. facaelis detected in about 10 hours, and S. aureus detected in about 11 hours. FIG. 10 shows the underside of four sensor plates where the sensor layer has undergone a detectable change in those areas of the sensor layer proximate to microorganism colonies in an adjacent immobilization matrix layer. Detected colonies in the studies subsequently yielded microbial dilutions which were immediately usable for further testing. A removable cover such as illustrated in FIGS. 8 and 9 eases the removal of detected colonies for further testing, such as antibiotic susceptibility testing or microbial identification.

While there have been described what are some of the presently preferred embodiments of the present invention, further changes and modification could be made by those skilled in the art without departing from the spirit and scope of the invention, and it is contemplated to claim all such changes and modifications. 

We claim:
 1. A sensor device comprising:a container under vacuum; and an immobilization layer within said container, for immobilizing a sample to be tested for the presence or enumeration of microorganisms.
 2. The sensor device of claim 1, further comprising:a sensor layer within said container and disposed in the proximity of the immobilization layer such that at least a portion of the sensor layer is capable of undergoing a detectable change due to the presence of microorganisms immobilized on and/or in the immobilization layer.
 3. The sensor device of claim 2, further comprising:a piercpable member in a wall of said container for being pierced during direct draw of blood from a patient.
 4. The sensor device of claim 2, wherein the sensor layer is constructed so as to undergo detectable localized changes which correspond to the presence of microorganism colonies in the immobilization layer.
 5. The sensor device of claim 4, wherein the sensor layer is an opaque layer.
 6. The sensor device of claim 2, wherein at least one of the immobilization layer and the sensor layer are opaque.
 7. The sensor device of claim 2, wherein at least one layer in the device has matrixes that adversely affect visualization of microorganism colonies.
 8. The sensor device of claim 7, wherein said at least one layer includes said sensor layer.
 9. The sensor device of claim 2, wherein the sensor layer sufficiently blocks the viewing of the test sample from the side of the sensor layer opposite from the immobilization layer.
 10. The sensor device of claim 2, wherein the sensor layer blocks the viewing with the eye or detecting with a detector, the test sample from the side of the sensor layer opposite from the immobilization layer.
 11. The sensor device of claim 2, further comprising an adhesive layer between at least one of a) the immobilization layer and the sensor layer, and b) the sensor layer and the container wall.
 12. The sensor device of claim 2, wherein the sensor layer is an opaque layer which changes in intensity of color in the presence of microorganisms.
 13. The sensor device of claim 2, wherein said immobilization layer comprises a gelling agent.
 14. The sensor device of claim 13, wherein said gelling agent is at least one of a solid gel, a semi-solid gel, or a powdered gel.
 15. The sensor device of claim 14, wherein said immobilization layer further comprises growth components for facilitating growth of microorganisms.
 16. The sensor device of claim 2, wherein said sensor layer is capable of undergoing a localized change in the ultraviolet, visible, and/or infrared spectrum.
 17. The sensor device of claim 16, wherein said localized change is detectable through said wall of said container.
 18. The sensor device of claim 2, wherein the sensor layer undergoes a detectable change in response to changes in one or more of oxygen, hydrogen, hydrogen sulfide, carbon dioxide, organic acid, nitrogen dioxide, ammonia and pH.
 19. The sensor device of claim 18, wherein said detectable change is detectable in the infrared, ultraviolet or visible spectrums.
 20. The sensor device of claim 18, wherein said sensor layer comprises an indicator having a change detectable by imaging, fluorescence or reflectance technology.
 21. The sensor device of claim 20, wherein the sensor layer exhibits a change in fluorescence intensity or visible color over a pH range of about 5.0 to 11.0.
 22. The sensor device of claim 12, further comprising a conditioning layer proximate to or within said immobilization layer for improving microorganism detection capabilities.
 23. The sensor device of claim 22, wherein said conditioning layer comprises at least one of lytic agents, lytic enzymes, surfactants and components to neutralize growth inhibitors.
 24. The sensor device of claim 12, wherein said immobilization layer comprises at least one of lytic agents, lytic enzymes, surfactants and components to neutralize growth inhibitors.
 25. The sensor device of claim 2, wherein said sensor layer comprises at least one indicator selected from fluorescein, coumarin, phenolphthalein, thymolphthalein, bromothymol blue, thymol blue, xylenol blue, ortho cresolphthalein and alpha-naphthol benzein.
 26. The sensor device of claim 2, wherein said sensor layer undergoes a change in response to an increase or decrease in a gas component due to microorganism metabolism.
 27. The sensor device of claim 2, wherein said sensor layer comprises at least one pigment for coloring the sensor layer.
 28. The sensor device of claim 27, wherein said pigment is a metal oxide.
 29. The sensor device of claim 28, wherein said pigment is an oxide of titanium, zinc, magnesium or iron.
 30. The sensor device of claim 20, wherein said sensor layer comprises a polymeric material.
 31. The sensor device of claim 2, wherein said container is a substantially flat substrate, a holding device open at one end, a closed box of rectangular cross section, or a bottle.
 32. The sensor device of claim 2, wherein said immobilization layer comprises an absorbent material for absorbing and immobilizing a test sample.
 33. The sensor device of claim 32, wherein said absorbent material is selected from filter paper, sponges, glass fibers, and celluloses.
 34. The sensor device of claim 32, further comprising a lytic agent on or in said immobilization layer, said lytic agent selected from saponin, digitonin, tween and polysorbitan monolaurate.
 35. The sensor device of claim 14, wherein said gelling agent is a solid gel, said solid gel comprising a dehydrated gel.
 36. The sensor device of claim 14, wherein said gelling agent is a semi-solid gel, said semi-solid gel comprising a partially dehydrated semi-solid gel.
 37. The sensor device of claim 14, wherein said gelling agent is a powder.
 38. The sensor device of claim 2, further comprising components for neutralizing inhibitors of microorganisms growth.
 39. The sensor device of claim 38, wherein said neutralizing components include at least one of a resin, ecosorb, and activated charcoal.
 40. The sensor device of claim 1, wherein said container is at a pressure of from 0 to 12 psi.
 41. A kit for collecting a blood sample from a patient and detecting the presence of microorganisms in the blood sample, comprising:a) a needle for insertion into a patient; b) a direct draw conduit connected to said needle; c) a container under vacuum having a pierceable member in a wall thereof; d) a piercing mechanism connected to said direct draw conduit, for piercing said pierceable member when said container is under vacuum to thereby allow the flow of blood from a patient into said container; wherein said container comprises therein an immobilization layer, for immobilizing a sample to be tested for the presence or enumeration of microorganisms, and a sensor layer disposed between the immobilization layer and a wall of the container, at least a portion of the sensor layer capable of undergoing a detectable change due to the presence of microorganisms immobilized on and/or in the immobilization layer.
 42. The kit of claim 41, wherein said container further comprises an adhesive layer between at least one of a) the immobilization layer and the sensor layer, and b) the sensor layer and the container wall.
 43. The kit of claim 41, wherein the sensor layer is opaque.
 44. The kit of claim 41, wherein said immobilization layer comprises a gelling agent.
 45. The kit of claim 44, wherein said gelling agent is at least one of a solid gel, a semi-solid gel, or a powdered gel.
 46. The kit of claim 41, wherein said immobilization layer further comprises growth components for facilitating growth of microorganisms.
 47. The kit of claim 41, wherein said container is a sealed container having a headspace above the immobilization layer.
 48. The kit of claim 47, further comprising a gas permeable membrane in a wall of said container.
 49. The kit of claim 48, further comprising a removable gas impermeable seal positioned proximate to said gas permeable membrane.
 50. The kit of claim 41, wherein said wall of said container is transparent or translucent.
 51. The kit of claim 41, wherein said sensor layer is capable of undergoing a localized change in the ultraviolet, visible, and/or infrared spectrum.
 52. The kit of claim 51, wherein said localized change is detectable through said wall of said container.
 53. The kit of claim 41, wherein the sensor layer undergoes a detectable change in response to changes in one or more of oxygen, hydrogen, hydrogen sulfide, carbon dioxide, ammonia, organic acid, nitrogen dioxide and pH.
 54. The kit of claim 53, wherein said detectable change is detectable in the infrared, ultraviolet or visible spectrums.
 55. The kit of claim 53, wherein said sensor layer comprises an indicator having a change detectable by imaging, fluorescence or reflectance technology.
 56. The kit of claim 55, wherein the sensor layer exhibits a change in fluorescence intensity or visible color over a pH range of about 5.0 to 11.0.
 57. The kit of claim 41, wherein said immobilization layer comprises an immobilized sample with microorganisms therein.
 58. The kit of claim 41, wherein said immobilization layer comprises a single gelling agent or a plurality of gelling agents.
 59. The kit of claim 58, wherein said gelling agents comprises one or more agents selected from gums, agars, agaroses, carageenans, bentonite, alginates, collagens, gelatins, fused silicates, water soluble starches, polyacrylates, celluloses, cellulose derivatives, polyethylene glycols, polyethylene oxides, polyvinyl alcohols, dextrans, polyacrylamides and polysaccharides.
 60. The kit of claim 43, wherein said immobilization layer comprises an upper layer for trapping microorganisms on a surface thereof, and a lower layer provided as a wicking agent to draw liquid sample through the upper layer.
 61. The kit of claim 58, wherein a first gelling agent is provided in an upper layer of the immobilization layer, and a second gelling agent is provided in a lower layer of said immobilization layer.
 62. The kit of claim 41, further comprising conditioning components proximate to or within said immobilization layer for improving microorganism detection capabilities.
 63. The kit of claim 62, wherein said conditioning components comprise at least one of lytic agents, lytic enzymes, surfactants and components to neutralize growth inhibitors.
 64. The kit of claim 41, wherein said sensor layer comprises silicone.
 65. The kit of claim 41, wherein the sensor layer is constructed so as to undergo detectable localized changes which correspond to the presence of microorganism colonies in the immobilization layer.
 66. The kit of claim 65, wherein the sensor layer is an opaque layer which changes from one color to a second color while remaining opaque in the presence of microorganisms.
 67. The kit of claim 65, wherein at least one of the immobilization layer and the sensor layer are opaque.
 68. The kit of claim 65, wherein at least one layer in the device has matrixes that adversely affect visualization of microorganism colonies.
 69. The kit of claim 68, wherein said at least one layer includes said sensor layer.
 70. The kit of claim 65, wherein the sensor layer sufficiently blocks the viewing of the test sample from the side of the sensor layer opposite from the immobilization layer.
 71. The kit of claim 65, wherein the sensor layer blocks the viewing with the eye or detecting with a detector, the test sample from the side of the sensor layer opposite from the immobilization layer.
 72. A method for taking a blood sample from a patient and for detecting microorganisms in said blood sample with the kit of claim 41, comprising:a) inserting a needle into a patient for withdrawing a blood sample from the patient; b) before or after step (a), piercing the stopper or septum of the container with the piercing mechanism, so that blood flows from the patient into said container, such that the sample becomes immobilized on or in the immobilization layer of the sensor device; removing the piercing mechanism from the stopper or septum and removing the needle from the patient; incubating the sensor device for a period of time so as to allow for growth of microorganism colonies; determining any localized changes in the sensor layer of the sensor device that correlate to the presence of microorganism colonies on or in the immobilization layer.
 73. The method of claim 72, wherein the blood sample is sufficiently opaque so as to interfere with visualization of microorganism colonies directly on said immobilization layer with the naked eye.
 74. The method of claim 72, wherein the sample is fluorescent.
 75. The method of claim 72, wherein the sample has a property in an electromagnetic region, and wherein said localized changes are determined with a detector which detects changes in said sensor layer in the same electromagnetic region.
 76. The method of claim 75, wherein the sample is fluorescent and the sensor layer undergoes a detectable change in response to changes in a gas component due to the presence or growth of microorganisms in said immobilization layer.
 77. The method of claim 72, wherein the sample is colored and/or fluorescent and the sensor layer comprises a fluorescent or visible pH indicator.
 78. The method of claim 77, wherein the immobilization layer is a powdered gel layer and the blood sample is a liquid blood sample which mixes with the powdered gel and gels so as to become immobilized and adhere to the sensor layer. 